Apparatus for controlling throttle valve and manufacturing method for the same and motor

ABSTRACT

An apparatus for controlling a throttle valve has a body member made of resin. The body member contains a motor for controlling a throttle valve. The motor has a yoke as a one of components thereof. The yoke is exposed to an intake passage at a slightly upstream side of the throttle valve. According to the arrangement, heat radiation from the motor is improved by intake airflow, and the throttle valve can be prevented from an icing malfunction.

CROSS REFERENCE TO RELATED APPLICATION

This application is based on Japanese Patent Applications No. 2001-32911filed on Feb. 8, 2001,No. 2001-34481 filed on Feb. 9, 2001, No.2001-91002 filed on Mar. 27, 2001, No. 2001-388220 filed on Dec. 20,2001, and No. 2001-388056 filed on Dec. 20, 2001, the contents of whichare incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an apparatus for controlling a throttlevalve, a method for manufacturing an apparatus for controlling athrottle valve and a motor apparatus.

2. Description of Related Art

If the temperature is cold, the valve of the throttle valve may get amalfunction by an icing. The icing is caused by moisture in the aircondensed within the intake pipe and froze on a contact portion among avalve of the throttle valve and an inner wall of the intake pipe.

JP-B-H07-49780 discloses an apparatus for controlling a throttle valvefor heating a vicinity of the valve by flowing an engine coolant througha part of a throttle valve housing for preventing it from getting cold.However, according to the arrangement disclosed in the publication, aconstruction is complex and also the cost may be expansive. Moreover,since the passage of the engine coolant is only arranged on a verylittle part of a portion of the throttle valve housing that is vicinityof the valve, if the throttle valve housing is made of a low heatconductive resin or the like, it may be difficult to prevent the valvefrom the icing malfunction.

JP-A-H07-166897 discloses an apparatus for controlling a throttle valvewith a motor. The motor is directly provided in a body member for thepurpose of improving heat radiation and a vibration resistance. A bodymember is formed of aluminum and the like in order to reduce its weightand improve its heat radiation, and a bearing holder member is attachedto the body member by means of such as screws or machine screws.

However, the above-described attachment of the motor housing and thebearing holder member to the body member by means of the screws or themachine screws undesirably causes the number of parts and the number ofassembly processes to be increased, which results in a seriousdifficulty to decrease the manufacture cost of the entire body of athrottle valve with a motor.

JP-A-H10-317998 discloses an apparatus for controlling a throttle valve.The apparatus has a throttle body having a water passage through whichan engine coolant flows. However, the water passage is only contact witha part of a circumference of an intake air passage. Therefore it isdifficult to heat the throttle valve body sufficiently. Further, in caseof the water passage being formed in the throttle body, it is importantto seal water in the passage.

SUMMARY OF THE INVENTION

Therefore it is an object of the present invention to provide anapparatus for controlling a throttle valve which is capable ofpreventing the icing malfunction effectively.

It is another object of the present invention to provide a motorapparatus which is capable of reducing number of parts and manufacturingcost.

It is a further object of the present invention to improve reliabilityof an apparatus for controlling a throttle valve made of resin.

According to an aspect of the present invention, a yoke of a motor forcontrolling a throttle valve is exposed to an intake air. Therefore themotor is cooled and a valve is prevented from the icing malfunction.

According to the other aspect of the present invention, a passagethrough which a heat conductive medium flows is arranged to pass througha vicinity of the motor. Therefore, the heat conductive medium is heatedby the motor and the valve is prevented from the icing malfunction.

According to the other aspect of the present invention, a bearing holdermember and a body member are made of the same resin and are welded. Thisarrangement makes it easy to manufacture and reduces number of parts.

According to the other aspect of the present invention, the body memberis made of resin and has a passage in which a heat conductive mediumflows. In case of the above arrangement, bridge portions are arranged inthe passage to strengthen the body member. In case of anotherarrangement, the body member is formed as a seamless body to provide areliable seal on the passage. In case of still another arrangement, thebody member provides pipes for an intake and an outlet of the passages,which are formed by joining separate parts. This arrangement providesreliable seal on the passage.

BRIEF DESCRIPTION OF THE DRAWINGS

Features and advantages of embodiments will be appreciated, as well asmethods of operation and the function of the related parts, from a studyof the following detailed description, the appended claims, and thedrawings, all of which form a part of this application. In the drawings:

FIG. 1 is a front view schematically showing an apparatus forcontrolling a throttle valve with a motor according to a firstembodiment of the present invention;

FIG. 2 is a sectional view schematically showing the apparatus takenalong a section line II-II in FIG. 1;

FIG. 3 is a front view schematically showing an apparatus forcontrolling a throttle valve with a motor according to a secondembodiment of the present invention;

FIG. 4 is a sectional view schematically showing the apparatus takenalong a section line IV-IV in FIG. 3;

FIG. 5 is a front view schematically showing an apparatus forcontrolling a throttle valve with a motor according to a thirdembodiment of the present invention;

FIG. 6 is a sectional view schematically showing the apparatus takenalong a section line VI-VI in FIG. 5;

FIG. 7 is a front view of an apparatus for controlling a throttle valvewith a motor according to a fourth embodiment of the present invention;

FIG. 8 is a cross-sectional view schematically showing the apparatustaken along a section line VIII-VIII in FIG. 7;

FIG. 9 is a sectional view schematically showing the entire body of anapparatus for controlling a throttle valve with a motor according to afifth embodiment of the present invention;

FIG. 10 is an enlarged sectional view schematically showing the motorshown in FIG. 9;

FIG. 11A shows the attached side surface of a bearing holder membershown in FIG. 10;

FIG. 11B shows a side surface opposite to FIG. 11A, that is, an outerside surface;

FIG. 12 is an enlarged sectional view schematically showing a motoraccording to a sixth embodiment of the present invention;

FIG. 13A shows the attached side surface of a bearing holder membershown in FIG. 12;

FIG. 13B shows a side surface opposite to FIG. 13A, that is, an outerside surface;

FIG. 14 is an enlarged sectional view schematically showing a motoraccording to a seventh embodiment of the present invention;

FIG. 15 is an enlarged sectional view schematically showing a motoraccording to a eighth embodiment of the present invention;

FIG. 16A shows the attached side surface of a bearing holder membershown in FIG. 15;

FIG. 16B shows a side surface opposite to FIG. 16A, that is, an outerside surface;

FIG. 17 is an enlarged sectional view schematically showing a motor.according to a ninth embodiment of the present invention;

FIG. 18 is a plane view of an apparatus for controlling a throttle valveaccording to a tenth embodiment of the present invention;

FIG. 19 is a sectional view on a sectional line XIX-XIX in FIG. 18;

FIG. 20 is a sectional view of an apparatus for controlling a throttlevalve according to an eleventh embodiment of the present invention;

FIG. 21 is a sectional view of an apparatus for controlling a throttlevalve according to a twelfth embodiment of the present invention; and

FIG. 22 is a sectional view of an apparatus for controlling a throttlevalve according to a thirteenth embodiment of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Herein after preferred embodiments of the present invention will bedescribed with reference to the drawings. In this invention, anapparatus for controlling a throttle valve has a motor for electricallycontrol an opening degree of the throttle valve or a mechanical link formanually control the opening degree of the throttle valve.

In the drawings, the same or similar components are designated by thesame reference numerals, and the explanation will not be repeated.

Referring to FIGS. 1 and 2, an apparatus for controlling a throttlevalve 1 has a throttle valve housing (body member) 10. The throttlevalve housing 10 has a part for forming a substantially cylindricalintake pipe 11 in which a valve 12 of a throttle valve is disposed, anda part for holding motor components such as a substantially cylindricalyoke 14. The motor components supported on the throttle valve housing 10provide a motor 13. In this embodiment, the throttle valve housing 10has the above-described two parts formed integrally and made of resin.In the intake pipe 11, a throttle valve shaft 15 for the valve 12 isprovided to be capable of rotating. The valve 12 opens and closes apassage in the intake pipe 11 by its rotating movement. The motor 13 isdisposed in the throttle valve housing 10 with its rotation shaftparallel to the throttle valve shaft 15. The output end of the motor 13is connected to power transmitting means 16 connected to the throttlevalve shaft 15. The output of the motor is transmitted to the valve 12through the power transmitting means 16 to control the opening degree.The opening degree of the throttle valve (opening degree of the valve)is detected by a throttle position sensor 17 and used for controllingthe throttle valve.

In this embodiment, the motor 13 is arranged so that a part of its yoke14 is exposed to the intake pipe 11 in a slightly upstream side of thevalve 12 and the yoke 14 directly comes into contact with a flow of airflowing in the intake pipe 11. The exposed part is designed not tointerfere with the rotating operation of the valve 12 as shown by arrowmarks in FIG. 2.

According to the above-described constitution, since the flow of air inthe intake pipe 11 directly comes into contact with the yoke 14, theheat radiation of the motor 13 is accelerated and the heat radiation ofthe motor is further improved without requiring any additional member.Thus, the deterioration of the torque of the motor due to the superheatof the motor is prevented. Therefore, a compact motor whose torque isthe smaller for a conventionally expected deterioration of torque can beset and the entire body of the apparatus is made compact.

Referring to FIGS. 3 and 4, in a second embodiment, an apparatus 2 has aheat conductive member. Since the basic constitution of the apparatus 2is the same as that of the apparatus 1 of the first embodiment, the sameexplanation will not be repeated. In the apparatus 2, a heat conductivemember 18 is arranged to come into contact with a part of the yoke 14.The heat conductive member 18 extends to an inside of the intake pipe 11so that the heat conductive member 18 comes into contact with the flowof air flowing in the intake pipe 11. As shown in FIGS. 3 and 4, thepart of the heat conductive member 18 exposed to the intake pipe 11provides with protruding and concavities in order to increase a heatradiation area and protrudes into the intake pipe 11. The part of theheat conductive member 18 protruding to the intake pipe 11 is designedto be located in a slightly upstream side of the valve 12 and not tointerfere with the rotating operation of the valve 12 as shown by arrowmarks in FIG. 4. Further, as apparent from FIG. 4, a part of the heatconductive member 18 forms a part of the outer surface of the throttlevalve housing 10 and is also exposed to outside air. The heat conductivemember 18 is made of a member of high thermal conductivity such as ametal.

According to such a constitution, heat generated in the motor 13 istransferred to the heat conductive member 18. Since the heat conductivemember 18 is exposed to the intake pipe 11, a flow of air in the intakepipe 11 comes into contact with the heat conductive member 18 to promotethe heat radiation of the motor. 13. According to this embodiment, sincea part of the heat conductive member 18 is also exposed to the outsideair, the heat of the motor is also radiated to the outside air.Therefore, a better heat radiation is obtained.

In this embodiment, although the heat conductive member 18 is exposed toboth of the intake pipe 11 and the outside air, the heat conductivemember 18 may be exposed to either of them. Further, according to thisembodiment, the protruding and concavities for increasing the heatradiation area are formed only on the part of the heat conductive member18 exposed to the intake pipe 11. However, similar protruding andconcavities may be provided on the part exposed to the outside air.

An apparatus 3 according to a third embodiment of the present inventionwill be described below. Referring to FIGS. 5 and 6, a part of a yoke 14is arranged so as to protrude and be exposed to an intake pipe 11. Thus,the yoke 14 directly comes into contact with the flow of air flowing inthe inlet pipe. Further, in the throttle valve with a motor 3, the heatconductive member 18 is arranged to come into contact with a part of theyoke 14, and the heat conductive member 18 extends to be exposed to theintake pipe 11 to come into contact with the flow of air flowing in theintake pipe 11. According to this embodiment, although only the yoke 14protrudes to the intake pipe 11, the part of the heat conductive member18 exposed to the intake pipe 11 may also protrude to the intake pipe 11similarly to the second embodiment. The part of the yoke 14 protrudingto the intake pipe 11 is designed to be located in a slightly upstreamside of a valve 12 and not to interfere with the rotating operation ofthe valve 12. As apparent from FIG. 6, a part of the heat conductivemember 18 forms a part of the outer surface of the throttle valvehousing 10 and is also exposed to outside air.

According to the above-described constitution, the same effect isobtained as the first embodiment and the second embodiment. Therefore,the heat radiation is improved compared with those of other embodimentsdescribed above.

In the embodiment, although the heat conductive member 18 is exposed toboth the intake pipe 11 and the outside air, the heat conductive membermay be exposed to only one of them. Further, in the embodiment, althoughprotruding parts and concavities are not especially formed on the partsof the heat conductive member 18 exposed to the intake pipe 11 and tothe outside air, the protruding parts and concavities for increasing theheat radiation area as described in the second embodiment may be formedon both or one of these parts.

Further, according to the above-described embodiments, one or both ofthe portion of the yoke 14 exposed to the inside of the intake pipe 11and the portion of the heat conductive member 18 exposed to the insideof the intake pipe 11 is disposed to a vicinity of the valve 12, asshown in the corresponding figures. By arranging as described above, itis possible to prevent the valve 12 from the icing malfunction since thevicinity of the valve 12 is heated by heat from the motor 13.

A fourth embodiment will be explained. Referring to FIGS. 7 and 8, theyoke 14 directly contacts with airflow in the intake pipe since a partof the yoke 14 is disposed to protrude and expose to the intake pipe 11.The portion of the yoke 14 protruding to the intake pipe 11 is locatedon a slightly upstream side of the valve 12, and is constructed so asnot to collide with a rotation of the valve 12.

Especially for this embodiment, the ring-shaped hollow portion, the ringpassage 19, is arranged in the pipe wall that construct the intakepassage so as to surround the valve 12 disposed in the intake pipe 11 asshown in FIGS. 7 and 8. The ring passage 19 is arranged so that a partthereof passes through a vicinity of the motor 13 as shown in FIG. 8. Aheat conductive medium, e.g. an engine coolant, passes the ring passage19 through.

By arranging as described above, in addition to the similar advantage ofhelping heat dissipation by being directly contact the yoke 14 with theair flow in the intake pipe 11, two advantages of helping heatdissipation from the motor 13 and preventing the valve 12 from the icingmalfunction are achieved by the heat conductive medium flowing throughthe ring passage 19. That is, if the valve may be frozen since thesurroundings of the valve 12 is cold, e.g. in case of low temperature,the surroundings of the valve is heated by the heat conductive mediumflowing in the ring passage 19. Therefore the valve 12 is prevented fromthe icing malfunction. On the other hand, if the temperature of themotor 13 rises, heat dissipation from the motor is improved bytransferring heat from the motor 13 to the heat conductive medium, sincethe part of the ring passage 19 is arranged to pass through the vicinityof the motor 13. A temperature of the heat conductive medium flowing inthe ring passage 19 may be controlled so as to accomplish theadvantages.

Since the ring passage 19 is arranged to surround the valve 12 disposedwithin the intake pipe 11, it is possible to prevent the valve from theicing malfunction reliably by heating an entirety of surroundings of thevalve 12 sufficiently, even if, for example the throttle valve housingis made of a low heat conductive resin or the like.

Although the engine coolant is utilized to pass through the ring passage19 in this embodiment, another heat conductive medium such as anotherhot water or a heated air may be utilized.

Incidentally, although the throttle valve housing having the abovedescribed ring shaped hollow portion (ring passage) 19 can bemanufactured by using the known several method. For example, it ispossible to obtain the above described ring passage 19 within thethrottle valve housing by composing the throttle valve housing by twoportions separated at a surface perpendicular to an axis of the intakepipe 11 where the ring shaped hollow portion 19 is separated intohalves, and assembling them to match ring grooves formed on respectiveportions. Further, a unitary and seamless throttle valve housing may beprovided by forming the hollow portion utilizing a resin blow formingmethod or a lost-wax resin forming method using a lost-wax type core orthe like.

The arrangement of this embodiment may be combined with the arrangementhaving the heat conductive member 18 described in the description of thesecond and third embodiment, in case of that, heat dissipation from themotor 13 is more improved.

As described above, the heat radiation of the motor is improved by asimple and inexpensive means by a simple structural change that does notneed any additional members, and such as a simple structural change andan additional heat conductive member. Therefore, since it is possible toprevent the deterioration of torque due to the superheat of the motor,the compact motor whose torque is the smaller for the conventionallyexpected deterioration of torque can be set. The entire body of thethrottle valve with a motor is made compact. Further, by using thesimilar means, on the other hand, it is possible to prevent the valvefrom the icing malfunction by using heat generated by the motor.Additionally, it is possible to prevent the valve from the icingmalfunction reliably and to improve heat dissipation of the motor byarranging the ring passage to surround the valve and flowing the heatconductive medium therein.

In the above-described embodiments, although the motor is disposed inthe upstream side of the valve, it is to be understood that similareffects may be obtained even when the motor is disposed in a downstreamside of the valve.

A fifth embodiment of an apparatus for controlling a throttle valve willbe described with reference to FIGS. 9, 10, 11A and 11B. In an apparatus113, a substantially cylindrical concavity 120 is provided in a part ofa body member 110 for accommodating the throttle valve 112 and forming apart of a motor housing. In this embodiment, the body member 110 is madeof resin. As shown in FIG. 10, a cylindrical yoke 114 of which both endsare opened is fixed to the inside surface of the concavity 120 providedin a part of the body member 110. A magnet 121 is fixed to the insidesurface of the yoke 114.

In the concavity 120, a surface 110 a inclined to be widened outward isprovided in the peripheral part of an opening part thereof. In the outerperipheral side of the inclined surface 110 a, an attachment referenceplane 110 b substantially perpendicular to the inside wall of theconcavity 120 is further extended. Further, in the outer peripheral sidethereof, a positioning frame 122 as an annular protruding part isprovided. On the bottom part of the concavity 120, a small concavity 123is further formed and a bearing 124 in a counter-output side is receivedin and attached to the small concavity. An armature 126 having arotation shaft 125 is accommodated in the concavity 120 in which theyoke 114 and the magnet 121 are installed. At this time, a part of therotation shaft 125 in the counter-output side is received and supportedby the bearing 124 in the counter-output side to be capable of rotating.

On the other hand, a part of the rotation shaft 125 in an output side issupported by a bearing 128 in the output side to be capable of rotating.The bearing 128 in the output side is disposed in a bearing holdermember 127 attached so as to cover up the concavity 120 in which thearmature 126 is accommodated. The part of the rotation shaft 125 in theoutput side passes through the bearing holder member 127 as well as thebearing 128 in the output side. The end part of the part of the rotationshaft 125 in the output side provides with a motor gear 129 forconnecting it to power transmitting means in order to transmit theoutput of the motor to the throttle valve 112.

FIGS. 11A and 11B respectively show the attached side surface of thebearing holder member 127 (that is, a side surface to be attached to thebody member 12) and a side surface opposite thereto (that is, an outerside surface). The bearing holder member 127 is substantially diskshaped and is made of the same resin as that of the body member 110. Asshown in FIG. 10, in this embodiment, brushes 130 are attached to thebearing holder member 127. That is, the bearing holder member 127 servesas a brush holder for holding the, brushes 130 at a proper position andallowing the brushes 130 to assuredly come into contact with acommutator 131. The bearing holder member 127 has a through hole 132through which the rotation shaft 125 passes on its central part.

In the periphery of the through hole 132 in the attached side surfaceside, a concavity 133 is provided to receive the bearing 128 in theoutput side. In the outermost peripheral part of the attached sidesurface of the bearing holder member 127, an annular positioningprotrusion 134 is provided. The positioning protrusion 134 has anoutside surface 134 a forming an alignment reference surface of thebearing holder member 134, and a top surface 134 b forming an attachmentheight reference surface. In other words, the outside surface 134 a isengaged with the inside surface 122 a of the annular positioning frame122. Further, the top surface 134 b abuts on the attachment referenceplane 110 b inwardly adjacent to the positioning frame 122.

On the attached side surface of the bearing holder member 127, anannular welding protrusion 135 is provided so as to correspond to theperipheral part of the opening of the concavity 120. More specifically,the outer side surface 135 a of the welding protrusion 135 is inclinedso that its width becomes narrower as it comes nearer to a top end ofthe protrusion 135. The inclined surface 135 a is located at a positioncorresponding to the inclined surface 110 a. Further, since a part ofthe welding protrusion 135 enters the concavity 120, the weldingprotrusion 135 is higher than that of the positioning protrusion 134.

When the bearing holder member 127 is attached to the body member 110,the inclined surface 135 a of the welding protrusion 135 is welded toand stuck to the inclined surface 110 a of the body member 110 by aresin welding process. In the resin welding process, both of theinclined surface 110 a and 135 a are melted and then set continuously.

In the embodiment, since the body member 110 and the bearing holdermember 127 are made of the same resin material, they are simply welded,stuck and fixed to each other by a resin welding method. Further, thebearing holder member 127 is precisely positioned in accordance with theabove-described operations of the positioning protrusion 134 and thepositioning frame 122 and the like.

The attachment of the bearing holder member 127 to the body member 110by the welding method can decrease the number of parts and the number ofassembly steps, compared with the attachment of a bearing holder memberto a body member by means of conventional screws or bolts. Theabove-described constitution can contribute to the decrease of themanufacture cost of the apparatus for controlling the throttle valvewith a built-in motor.

FIG. 12 shows a sixth embodiment of an apparatus 213. The apparatus 213is the same as the apparatus 113 shown in the first embodiment exceptthe constitution of a bearing holder member 227 and the constitution ofa part of a body member 210.

An annular protrusion 240 is provided adjacently the periphery of theopening of a concavity 220 provided in the body member 210 in which anarmature 126 is accommodated. A top surface 240a of the protrusion 240forms an attachment reference plane. The inside surface of theprotrusion 240 forms a part of the inner side surface of the concavity220, and is substantially perpendicular to the attachment referenceplane.

As shown in FIG. 12, an outside surface 240 b of the protrusion 240 isinclined so that the lower part of the protrusion 240 is widenedoutward. In the outer part of the annular protrusion 240, an annularpositioning frame 122 is further provided. An annular groove 210 a isformed between the protrusion 240 and the positioning frame 122.

FIGS. 13A and 13B respectively show the attached side surface of thebearing holder member 227 and a side surface opposite thereto. Thebearing holder member 227 is substantially disk shaped, like the bearingholder member 127 of the first embodiment. The bearing holder member 227has the through hole 132 through which the rotation shaft 125 passes onits central part. In the periphery of the through hole 132 in theattached side surface side, the concavity 133 is provided to receive thebearing 128.

In the bearing holder member 227, an annular flat protrusion 244 isprovided in the periphery adjacently the opening of the concavity 133.The top surface 244 a of the protrusion 244 forms the attachment heightreference surface of the bearing holder member 227. The inside surfaceof the protrusion 244 forms a part of the inner side surface of theconcavity 133. The protrusion 244 is extended to a range that when thebearing holder member 227 is attached to the body member 210, at least apart of the top surface 244 a abuts on the top surface 240 a of theprotrusion 240 of the body member 210. The top surface 240 a abuts onthe top surface 244 a so that a positioning operation in the directionof height (right and left directions in FIG. 12) is carried out.

In the outermost peripheral part of the bearing holder member 227, anannular positioning and welding protrusion 242 is provided. The outsidesurface 242 a of protrusion 242 is engaged with the positioning frame122 provided on the body member 210. The engagement makes it possible toalign the bearing holder member 227. On the other hand, the insidesurface 242 b of the protrusion 242 is inclined so as to correspond tothe inclined surface 240 b of the body member 210. That is, while thebearing holder member 227 is attached to the body member 210, theprotrusion 242 of the bearing holder member 227 is fitted to the groove210 a.

When the bearing holder member 227 is attached to the body member 210,the inclined surface 242 b of the bearing holder member 227 is welded toand stuck to the inclined surface 240 b of the body member 210. In theembodiment, the body member 210 and the bearing holder member 227 aremade of the same resin material, and they are simply welded, stuck andfixed to each other by a resin welding method. Further, as mentionedabove, the bearing holder member 227 is precisely positioned.

Further, in this embodiment, when the protrusion 240 abuts on theprotrusion 244 inward the welding part, and the output side of the motoris disposed in an upper part (that is, when the bearing holder member227 side is disposed in the upper part), the inclination of the weldingpart descends outward, so that molten resin does not enter the concavity220. In other words, there are formed the welding part having theinclined surface 240 a formed so as to allow the molten resin to flowoutward, and having molten resin entry preventing means including theabutting part of a part of the bearing holder member 227 and a part ofthe body member 210, in which the part is located inward the weldingpart. In such a manner, since the molten resin is prevented fromentering the motor, a manufacture is facilitated and the quality isimproved due to the deterioration of failure rate in a motor part.

FIG. 14 shows a seventh embodiment of an apparatus 313. The apparatus313 is substantially the same as the apparatus 213 disclosed in thesixth embodiment except for an arrangement of a portion where a bearingholder member 327 and a body member 310 are joined.

A ring like protrusion 340 and a ring like small protrusion 341 arelocated as shown in FIG. 14. The protrusion 340 is located next to anopening of a concavity 320. The protrusion 340 surrounds the opening.The small protrusion 341 is provided by extending a portion of the bodymember 310 further from a top surface of the protrusion 340. The smallprotrusion 341 provides a dam portion for damming molten resin flow whenthe bearing holder member 327 is welded on the body member 310. Theprotrusion 340 corresponds to the protrusion 240 in the sixthembodiment.

The arrangement and the functions of the parts of the bearing holder 327in this embodiment are substantially the same as those of the sixthembodiment. Therefore, the explanation will not be repeated.

In this embodiment, a top surface of the ring shaped protrusion 344 isarranged to be not contact with a top surface of the protrusion 340 ofthe body member 310 as shown in FIG. 12.

Attaching the bearing holder member 327 to the body member 310 isperformed by welding inclined surfaces on the protrusions 242 and 340.It is possible to fix them easily by the welding process since the bodymember 310 and the bearing holder member 327 are made of the same resinin this embodiment too. Also, it is possible to fix the bearing holdermember 327 with an accurate positioning.

A dam for damming molten resin that flows out from the portions forfixing the body member 310 and the bearing holder member 327 when thewelding process is carried out is provided. Thereby, it is possible toease the manufacturing and to improve a quality such as a reducingfailure rate of the motor.

Although the embodiment employs both of the arrangements, the inclinedsurfaces and the dam, it is possible to employ only one of thosearrangements as a means for preventing a leak of the molten resin.

FIG. 15 shows an eighth embodiment of an apparatus. The apparatus 413has a bearing holder member 427 on a counter-output side. The bearing128 in the output side is directly attached to a body member 410 and thebearing 124 in the counter-output side is attached to a bearing holdermember 427 which is welded, stuck and fixed to the body member 410.

A substantially cylindrical concavity 420 is provided in the body member410. In this embodiment, the body member 410 and the baring holdermember 427 are made of the same resin.

A inclined surface 410 a to be widened outward is provided in theperipheral part of an opening of the concavity 420. An attachmentreference plane 410 b substantially perpendicular to the inside wall ofthe concavity 420 is further extended. Further, in the outer peripheralside thereof, a positioning frame 422 as an annular protruding part isprovided.

On the bottom part of the concavity 420, a hole 432 through which theoutput side of the rotation shaft 125 passes is provided at its center,a small concavity 433 is formed in the periphery of the through hole 432and the bearing 128 is received in and attached to the concavity 433.Further, the brushes 130 are attached to the bottom part of theconcavity 420. The brushes 130 are held at a suitable position to allowthe brushes to assuredly come into contact with a commutator 131. Thearmature 126 having the rotation shaft 125 is accommodated in theconcavity 420 in which the yoke 114 and the magnet 121 are installed. Atthis time, the output side part of the rotation shaft 125 passes throughthe bearing 128 and is supported to be capable of rotating and passesthrough the through hole 432. The motor gear 129 is attached on the endof the rotation shaft 125.

On the other hand, the counter-output side part of the rotation shaft issupported by the bearing 124 to be capable of rotating. The bearing 124is disposed in the bearing holder member 427 attached so as to cover upthe concavity 420.

FIGS. 16A and 16B respectively show the attached side surface of thebearing holder member 427 and a side surface opposite thereto. Thebearing holder member 427 is substantially disk shaped and is made ofthe same resin as that of the body member 410. In this embodiment, thebearing holder member 427 has a concavity 423 provided at the centralpart of the attached side surface to receive the bearing 124. In theoutermost peripheral part of the attached side surface of the bearingholder member 427, an annular positioning protrusion 434 is provided.The positioning protrusion 434 has outside surface 434 a forming analignment reference surface of the bearing holder member 427 and topsurface 434 b forming an attachment height reference surface. Theoutside surface 434 a engages with the inside surface of the annularpositioning frame 422 provided around the opening part of the concavity420 to align the bearing holder member 427. Therefore, an alignmentbetween the rotation shaft 125 and the counter-output side bearing 124supported on the bearing holder member 427 is carried out. Further, thetop surface 434 b (that is, a surface facing the body member 410 towhich the positioning protrusion is attached) abuts on an attachmentreference plane 410 b inwardly adjacent to the positioning frame 422 toposition the bearing holder member 427 in the direction of height.

An annular welding protrusion 435 is provided so as to correspond to theperipheral part of the opening part of the concavity 420. Morespecifically, the welding protrusion 435 has its outside surface 435 ainclined so that its width becomes narrower as it comes nearer to theend of the protrusion 435. The inclined surface 435 a is located at aposition corresponding to the inclined surface 410 a. Further, since apart of the welding protrusion 435 enters the opening part of theconcavity 420, the height of the welding protrusion 435 is higher thanthat of the positioning protrusion 434.

When the bearing holder member 427 is attached to the body member 410,the inclined surfaces 410 a and 435 a are welded. The means forpreventing the concavity form entering the molten resin may be alsoapplied to the eighth embodiment.

A ninth embodiment of an apparatus 513 is shown in FIG. 17. Theapparatus 513 of the embodiment is the same in an aspect that the motorcomponents are housed in a concavity 520 that is substantiallycylindrical and is formed in a body member 510. However, the embodimentemploys an arrangement in which a motor housing 550 houses the othermotor components and is housed in the concavity 520 as shown in FIG. 17.

In detail, the motor housing 550 is cup-shaped and performs to assemblethe motor components on predetermined positions therein and to supportthe motor components integrally. The yoke 114 is fixed on an insidesurface of the motor housing 550, and the magnet 121 is fixed on aninside surface of the yoke 114. The counter-output side bearing 124 ishoused and fixed in a small concavity 551 formed on a bottom of themotor housing 550. The armature 126 having the rotation shaft 125 ishoused in an inner space 552 of the motor housing 550 where the yoke 114and the magnet 121 are disposed.

When the armature 126 is housed in the motor housing 550, acounter-output side end of the rotation shaft 125 is received andsupported by the counter-output side bearing 124. The output sidebearing 128 disposed in the bearing holder member 527 rotatably supportsan output side end of the rotation shaft 125. The bearing holder member527 is attached on the cup-shaped motor housing 550 with the armature126 so as to cover the motor housing 550. The output side end of therotation shaft 125 is disposed to pass through the output side bearing128 and the bearing holder member 527, and a motor gear 129 for linkingwith a power transmitting means and transferring an output of the motorto the throttle valve is attached on a distal end thereof.

A surface 510 a inclined to enlarge toward radial outside is formed on aradial outside of an opening of the concavity 520. An assemblingreference plane surface 510 b which is substantially perpendicular to aninside wall of the concavity 520 is formed and extended on a radialoutside of the inclined surface 510 a. A positioning frame 122, which isa ring shaped protrusion, is disposed on a radial outside of theassembling reference plane surface 510 b. The body member 510 is alsomade of resin in this embodiment.

The arrangement and the functions of the parts of the bearing holder 527in this embodiment are substantially the same as those of the bearingholder member 127 of the first embodiment. Therefore, the explanationwill not be repeated. However, in this embodiment, differently from thecase of the first embodiment, the motor housing 550 is attached on theend surface of the welding protrusion 535 as shown in FIG. 17. During anassemble of the apparatus 513, first the motor housing 550 housing thecomponent of the motor is attached on the bearing holder member 527,then the bearing holder member 527 is attached on the body member 510 sothat the motor housing 550 is housed in the concavity 520.

Attaching the bearing holder member 527 to the body member 510 isperformed by a resin welding process as well as the first embodiment.

As described above, according to the embodiments, the apparatus forcontrolling the throttle valve, especially a motor apparatus, isassembled by welding the bearing holder member to the body member.Therefore, the number of parts and the number of assembling steps aredecreased compared with the conventional case in which the small machinescrews or bolts are used, which can contribute to the decrease of themanufacture cost.

The bearing holder member and the body member may be made of materialsuch as PBT (Polybutylene terephthalate) and PPS (Polyphenylene sulfide)which are categorized in a thermoplastic engineering resin.

The welding between the bearing holder member and the body member may becarried out by methods such as a laser welding, an ultrasonic weldingand a vibrating welding.

Although the embodiments are the throttle valve, that is the apparatusfor controlling the throttle valve, the present invention may beimplemented on a motor apparatus for other purposes. Although theexamples of a DC motor are given, equivalent effects may be obtained byother motors such as a step motor.

A tenth embodiment of an apparatus for controlling a throttle valve willbe explained. In this embodiment, the apparatus for controlling thethrottle valve provides manual operations and controls of the throttlevalve. FIGS. 18 and 19 shows an apparatus for controlling a throttlevalve of a tenth embodiment.

An apparatus 600 has a valve housing 610 forming an intake passage 602,a valve shaft 615 supported in the valve housing 610 to be capable offreely rotating, a valve 612 fixed to the valve shaft 615 to vary theopening area of the intake passage 602, a transmitting member 616 fortransmitting a turning force to the valve shaft 615 and a turning anglesensor 617 for detecting the turning angle of the valve shaft 615. Asshown in FIG. 19, the apparatus 600 is arranged, when it is mounted on avehicle, so that its intake upstream side communicates with an intakeair duct having an air filter 604 in an airtight manner, and so that itsintake downstream side communicates with an internal combustion engine608 having an intake manifold in an airtight manner.

The valve housing 610 is made of a resin material and forms asubstantially cylindrical intake pipe as shown in FIGS, 18 and 19. Thevalve housing 610 has the intake passage 602 in the air intake pipe.

As shown in FIG. 19, the valve housing 610 includes an outer peripheralwall part 611 forming the intake passage 602 therein, and bearing parts663 and 664 for supporting both end portions 661 and 662 of the valveshaft 615 to be capable of freely rotating. The outer peripheral wallpart 611 has a predetermined thickness so as to form a circular sectionof the air intake passage as shown in FIG. 19. The bearing parts 663 and664 are formed in substantially cylindrical forms (see FIG. 19), andtheir inner parts directly bear both end portions 661 and 662 so thatthe valve shaft 615 is capable of freely rotating. The bearing parts 663and 664 provide bridge portions to connect an inner wall and an outerwall of the wall 611.

The detail of the structures and functions of the valve housing 610,specially, the outer peripheral wall part 611 and the bearing parts 663and 664 which are the main parts will be described below.

The valve shaft 615 is formed in a substantially cylindrical shape andis supported by both of the bearing parts 663 and 664 to be capable offreely rotating. One end portion 661 of the valve shaft 615 isaccommodated in the bearing part 663. The other end portion 662 passesthrough the bearing part 664 and an external force for externallyrotating the valve shaft 615 is exerted thereon. The lever 616 isengaged with an accelerator pedal (not shown) on vehicle through anaccelerator wire (not shown).

The external force exerted on the valve shaft 615 is not limited to amechanical external force interlocking with the movement of theaccelerator pedal through the lever 616. An electrical external force bya driving motor for driving the valve shaft 615 so as to freely rotatemay be employed.

The valve 612 is fixed to the valve shaft 615 so as to make the openingarea of the intake passage 602 variable and disposed in the intakepassage 602 to be capable of rotating together with the valve shaft 615.

As shown in FIG. 19, when the turning angle of the valve shaft 615 islocated at a completely closed position, that is, when the valve 612 islocated at its completely closing position, the valve 612 is held at aposition shown by a solid line. The valve 612 makes the opening area ofthe air intake passage 10 a none, that is, the valve body makes theintake passage 602 (specifically, a cross-section) close. Further, whenthe valve 612 is located at its completely opening position, the valve612 is held at a position shown by a two-dot chain line so as tocompletely open the opening area of the intake passage 602, that is,held substantially perpendicularly to the cross-section of the intakepassage 602.

Therefore, since the valve 612 is ordinarily freely or movably fitted tothe intake passage 602 within a range in the vicinity of a positionwhere the turning angle of the valve shaft 615 is located at itscompleted closed position. Especially at the completely closingposition, the valve 612 is fitted to the intake passage 602 so as toclose the intake passage 602. Therefore, so-called icing is susceptibleto occurring, since the valve 612 or the valve shaft 615 is apt to befrozen with the valve hosing 610 due to vapor condensation caused byleaving the device in a low temperature environment. The structuralfeatures of the present invention for preventing the icing state will bedescribed hereinafter.

The turning angle sensor 617 detects the turning angle of the valveshaft 615, and is a known sliding resistor for varying a resistancevalue in accordance with the turning angle of the valve shaft 615.

There will be described below the structural feature for heating thevalve housing 610, particularly the outer peripheral wall part 611forming the intake passage 602 and the bearing parts 663 and 664 forrotatably supporting the valve shaft 615 which are the main parts.

As shown in FIGS. 18 and 19, in the outer peripheral wall part 611, ahollow part 665 having an annular space formed between the innerperipheral wall 666, outer peripheral wall 667 and both axial end walls.The bearing parts 663 and 664 bridges both of the peripheral walls.

More specifically, the inner peripheral wall 666 defines the intakepassage 602. The bearing parts 663 and 664 are fixed in an airtightmanner between the peripheral walls so as to bridge over them.Therefore, the hollow part 665 is formed in a substantially annular formto surround the intake passage 602 at a radial outside of the valve 612.

The outer peripheral wall 667 has connecting pipes 668 and 669 forintroducing and discharging a heat conductive medium, such as hot water.As shown in FIGS. 18 and 19, the connecting pipes 668 and 669 arerespectively connected to pipe 670 made of rubber in an airtight manner.The pipes 670 provide with clamps 671 as dislocation preventing means.

The heat conductive medium may be fluid capable of circulating and beingintroduced to and discharged from the space R and may be either liquidor gas. In the embodiments of the present invention, the heat conductivemedium will be described as the hot water, hereinafter.

The hot water enters the annular hollow part 665 from the connectingpipe 668 in the direction shown by an arrow mark in FIG. 18, flows alongthe inner peripheral wall 666. The hot water especially flows on theouter periphery of the wall 666 and the outer peripheries of the bearingportions 663 and 664, and then flows out from the connecting pipe 669.

Thus, the hot water passes through the annular hollow part 665, so thatthe hollow part 665 can form a heat conductive medium passage (refer itto as a hot water passage, hereinafter). Since the airtight hollow part665 is formed in the valve housing 610 made of a resin material, thecapacity of the hot water passage 665 is increased depending on thesize. Therefore, since the apparatus can increase the capacity of thehot water passage, a heating capability for preventing frost isimproved.

In addition, since the hot water introduced to the hollow part 665 candirectly heat the wall 666 defining the intake passage 602 and thebearing portions 663 and 664, the wall 666, the valve 612 and the valveshaft 615 are assuredly prevented from being frozen.

As a method for producing the valve housing 610 made of the resinmaterial, the hollow part 665 may be formed by employing a resin blowmolding method, a resin molding method by using a lost-wax type core andthe like. In case of using the resin blow molding method or the resinmolding method by the lost-wax core, it is possible to provide aseamless type valve housing 610 can be integrally formed. In this case,at least one of the pipes 668 and 669 may be used as an opening tointroduce a pressurized air in the resin blow molding method or tosupport the core in a molding cavity.

Thus, reliability of the air-tightness such as an anti-air leakage isimproved in comparison with a conventional arrangement which usesairtight members such as seal gaskets.

FIG. 20 shows a eleventh embodiment of an apparatus for controlling athrottle valve. In this embodiment, an insert core 673 is added to theinner peripheral wall 666.

As shown in FIG. 20, the insert core 673 made of annular metal isprovided in the vicinity of the completely closing position of the valve612. Accordingly, the insert core 673 made of a metal material having athermal conductivity higher than that of the resin material can bedisposed so that a heating capability is improved.

Since the insert core 673 is arranged within a range in the vicinity ofa position where the valve 612 is completely closed, that is, within arange in which the valve 612 is freely or movably fitted to an intakepassage 602 or fitted to the intake passage, a frost prevention isassuredly implemented.

A method for providing the insert core 673 in a valve housing 610 is notlimited to a method for casting the insert core 673 when the valvehousing 610 is subjected to a resin molding method. A method may beemployed for dividing the valve housing 610, performing the resinmolding method for the valve housing, and then holding the insert core673 between the divided valve housing parts as in an embodimentdescribed below.

FIG. 21 shows a twelfth embodiment of an apparatus for controlling athrottle valve. In this embodiment, the valve housing 610 is made of twoparts. The hollow part 665 is formed by grooves formed on the partsrespectively.

As shown in FIG. 21, the valve housing 610 is axially divided into afirst housing 680 and a second housing 690 along an axis of the intakepassage, and made of a resin material upon resin molding. The firsthousing 680 has a wall part 681 and bearing parts 682 and 683. Thesecond housing 690 has a wall part 691 and bearing parts 692 and 693.The wall parts 681 and 691 form the wall portion 611 that defines theintake passage 602 and the annular hollow part 665 therein. The firsthousing 680 is joined to the second housing 690 by employing a vibrationweld sticking method and the like.

As shown in FIG. 21, connecting parts 684 and 685 are provided on thefirst housing 680 for introducing hot water to or discharging it fromthe hollow part 665. The connecting parts 684 and 685 may be provided ineither the first housing 680 or the second housing 690.

Accordingly, the capacity of the hot water circulating passage of thehollow part 15 is increased in accordance with the size of an interiorspace of the hollow part 665. A heating capability for frost preventionis improved. The hot water introduced to the hollow part 665 candirectly heat the wall 666 defining the intake passage 602, and thebearing parts 682, 683, 692 and 693. The intake passage 602, the valve612 and the valve shaft 615 are assuredly prevented from being frozen.

Further, the valve housing 610 is divided, and the divided valvehousings are formed of a resin material. The valve housing 610 subjectedto a resin molding method, that is, the die designs of the first housing680 and the second housing 690 is designed more easily, compared with anintegral resin molding work by using a blow molding method and the like.Therefore, a manufacture cost for the resin molding such as the cost ofthe dies is reduced. Consequently, the inexpensive apparatus forcontrolling the throttle valve can be provided.

As shown in FIG. 21, the insert core 673 may be sandwiched between thefirst housing 680 and the second housing 690. Thus, the insert core 673made of metal having a thermal conductivity higher than that of theresin material can be provided as in the above embodiments. In addition,since the insert core 673 is arranged within a range in the vicinity ofa position where the valve 612 is completely closed, that is, within arange in which the valve 612 is freely or movably fitted or fitted tothe intake passage 602, frost prevention is assuredly attained.

FIG. 22 shows a thirteenth embodiment of an apparatus for controlling athrottle valve. In this embodiment, one of the connecting pipes isformed by a part 686 integrally formed on the first housing 680 and apart 696 integrally formed on the second housing 690. In the samemanner, another one of the connecting pipes is formed by a part 687integrally formed on the first housing 680 and a part 697 integrallyformed on the second housing 690.

Accordingly, the connecting pipes may provide with bulges 676 and 677for preventing the dislocation of pipes 670 by taking the designs ofdies into consideration.

The dislocation of the pipes 670 is assuredly prevented, so that thelowering of reliability in the air-tightness such as an air leakage issurely prevented.

Although the present invention has been described in connection with thepreferred embodiments thereof with reference to the accompanyingdrawings, it is to be noted that various changes and modifications willbe apparent to those skilled in the art. Such changes and modificationsare to be understood as being included within the scope of the presentinvention as defined in the appended claims.

1-13. (Canceled).
 14. An apparatus for controlling a throttle valve forregulating an amount of air flowing in an intake pipe of an internalcombustion engine, comprising: a body member made of a resin which has aconcavity for housing a motor component; and a bearing holder membermade of the same resin of the body member which is formed to cover theconcavity and supports a bearing member for supporting an end of arotation shaft of the motor component, wherein the bearing holder memberis fixed on the body member by a welding.
 15. The apparatus forcontrolling the throttle valve according to claim 14, wherein the motorcomponent includes: a yoke fixed in the concavity formed on the bodymember; a magnet attached on an inside of the yoke; an armature having arotation shaft which inserted into an inside of the yoke where themagnet is attached; bearing member which supports end of the rotationshaft, and is supported on the body member; and bearing member whichsupports another end of the rotation shaft, and is supported on thebearing holder member.
 16. The apparatus for controlling the throttlevalve according to claim 14, wherein a portion where the body member andthe bearing holder member are fixed by the welding is an inclinedsurface which is arranged so that molten resin flows outside of theconcavity.
 17. The apparatus for controlling the throttle valveaccording to claim 14, wherein the body member provides a dam portion byan extended part thereof, the dam portion being located on an inside ofa portion where the body member and the bearing holder member are fixedby the welding, the dam portion damming molten resin.
 18. The apparatusfor controlling the throttle valve according claim 14, wherein the bodymember and the bearing holder member provides a positioning means byengaging portions thereof, the positioning means being capable ofaligning the rotation shaft and the bearing member supported on thebearing holder member.
 19. The apparatus for controlling the throttlevalve according to claim 14, wherein the bearing member supported on thebearing holder member supports an output side or a counter-output sideend of the rotation shaft.
 20. The motor apparatus, comprising: a bodymember made of a resin having a concavity for housing a motor component;and a bearing holder member fixed on the body member, which supports abearing member for supporting an end of a rotation shaft of the motorcomponent, wherein the body member and the bearing member are made ofthe same resin, and the bearing holder member is fixed on the bodymember by a welding. 21-24. (Canceled).